US8501010B2 - Di- and mono-alkoxysilane functionalized polymers and their application in the Bayer process - Google Patents
Di- and mono-alkoxysilane functionalized polymers and their application in the Bayer process Download PDFInfo
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- US8501010B2 US8501010B2 US13/645,613 US201213645613A US8501010B2 US 8501010 B2 US8501010 B2 US 8501010B2 US 201213645613 A US201213645613 A US 201213645613A US 8501010 B2 US8501010 B2 US 8501010B2
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- QYBRPGVELLVPQL-OAWPRRBVSA-N C.C.C.C.CCN(C)CC.C[3H]N(C)CC Chemical compound C.C.C.C.CCN(C)CC.C[3H]N(C)CC QYBRPGVELLVPQL-OAWPRRBVSA-N 0.000 description 3
- OTMSDBZUPAUEDD-UHFFFAOYSA-N CC Chemical compound CC OTMSDBZUPAUEDD-UHFFFAOYSA-N 0.000 description 3
- ZJJKCWPZCQOBPA-DGPROHSZSA-N CC(=O)C[C@@H](C)C(=O)ON.CC(=O)[C@H](C)CC(=O)ON Chemical compound CC(=O)C[C@@H](C)C(=O)ON.CC(=O)[C@H](C)CC(=O)ON ZJJKCWPZCQOBPA-DGPROHSZSA-N 0.000 description 3
- DOGIHOCMZJUJNR-SECBINFHSA-N CCCC[C@H](C)CCC Chemical compound CCCC[C@H](C)CCC DOGIHOCMZJUJNR-SECBINFHSA-N 0.000 description 3
- LSOSITKUNLTSJD-SFYZADRCSA-N CCC[C@@H](C[C@@H](C)C(N)=O)C(=O)OC Chemical compound CCC[C@@H](C[C@@H](C)C(N)=O)C(=O)OC LSOSITKUNLTSJD-SFYZADRCSA-N 0.000 description 3
- BOORRMXFQOBCRL-FVGYRXGTSA-N C.CCCCNC(=O)[C@@H](C)CCC Chemical compound C.CCCCNC(=O)[C@@H](C)CCC BOORRMXFQOBCRL-FVGYRXGTSA-N 0.000 description 2
- 0 C.C.C.C.CCN(C)CC.[1*]O[Si](C)(CN(C)[3H]C)O[1*] Chemical compound C.C.C.C.CCN(C)CC.[1*]O[Si](C)(CN(C)[3H]C)O[1*] 0.000 description 1
- NRXLLFXXIGPBKW-UHFFFAOYSA-N C.CCCCC.CCCCNC(C)=O Chemical compound C.CCCCC.CCCCNC(C)=O NRXLLFXXIGPBKW-UHFFFAOYSA-N 0.000 description 1
- FZOGRCOINIULAG-PAWRJENLSA-N CCCC(=O)[C@@H](CCC)CC(=O)O.CCC[C@@H]1CC[C@@]12CC2=O.O=CO Chemical compound CCCC(=O)[C@@H](CCC)CC(=O)O.CCC[C@@H]1CC[C@@]12CC2=O.O=CO FZOGRCOINIULAG-PAWRJENLSA-N 0.000 description 1
- MZEWYGQWPJQDKM-DBFXGHTMSA-N CCCC(=O)[C@@H](CCC)CO(C)O.CCC[C@@H](C)CCCC(C)=O.COO Chemical compound CCCC(=O)[C@@H](CCC)CO(C)O.CCC[C@@H](C)CCCC(C)=O.COO MZEWYGQWPJQDKM-DBFXGHTMSA-N 0.000 description 1
- XZABSCBORTXXGN-DBFXGHTMSA-N CCCC(=O)[C@@H](CCC)COCO.CCC[C@@H](C)CCCC(C)=O.O=CO Chemical compound CCCC(=O)[C@@H](CCC)COCO.CCC[C@@H](C)CCCC(C)=O.O=CO XZABSCBORTXXGN-DBFXGHTMSA-N 0.000 description 1
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01F—COMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS
- C01F7/00—Compounds of aluminium
- C01F7/02—Aluminium oxide; Aluminium hydroxide; Aluminates
- C01F7/46—Purification of aluminium oxide, aluminium hydroxide or aluminates
- C01F7/47—Purification of aluminium oxide, aluminium hydroxide or aluminates of aluminates, e.g. removal of compounds of Si, Fe, Ga or of organic compounds from Bayer process liquors
Definitions
- This invention relates to compositions of matter and methods of using them to treat scale in various industrial process streams, in particular certain silane based polymers that have been found to be particularly effective in treating aluminosilicate scale in a Bayer process stream.
- the Bayer process is used to manufacture alumina from raw Bauxite ore. Because the Bayer process uses caustic solution to extract alumina values from bauxite it is cost prohibitive to perpetually use fresh caustic solution. As a result, a caustic solution known as “liquor” and/or “spent liquor” is recycled back from later stages of the Bayer process to earlier stages and thus forms a fluid circuit. For the purposes of this application, this description defines the term “liquor”. The recycling of liquor within the fluid circuit however has its own complexities.
- Raw Bauxite contains silica in various forms and amounts. Some of the silica is unreactive so it does not dissolve and remains as solid sand or mud within the Bayer circuit. Other silica (for example clays and kaolinite) is reactive and dissolves in caustic when added into Bayer process liquors. As spent liquor flows repeatedly through the liquor circuit of the Bayer process, the concentration of silica in the liquor increases eventually to a point where it reacts with aluminum and soda to form insoluble aluminosilicate scale. Aluminosilicate scale comes in at least two forms, sodalite and cancrinite. These and other forms of aluminosilicate scale are commonly referred to, and for purposes of this application define, the terms “desilication product” or “DSP”.
- DSP can have a formula of 3(Na 2 O.Al 2 O 3 .2SiO 2 .0-2H 2 O).2NaX where X represents OH ⁇ , Cl ⁇ , CO 3 2 ⁇ , SO 4 2 ⁇ .
- DSP has an inverse solubility (precipitation increases at higher temperatures) and can precipitate as fine scales of hard insoluble crystalline solids, its accumulation in Bayer process equipment is problematic. As DSP accumulates in Bayer process pipes, vessels, heat transfer equipment, and other process equipment, it forms flow bottlenecks and obstructions and can adversely affect liquor throughput. In addition because of its thermal conductivity properties, DSP scales on heat exchanger surfaces reduce the heat exchanger efficiency.
- a “desilication” step in the Bayer process is used to reduce the concentration of silica in solution by precipitation of silica as DSP as a free precipitate rather than as scale. While such desilication reduces the overall silica concentration within the liquor, total elimination of all silica is impractical and changing process conditions within various parts of the circuit (for example within heat exchangers) can lead to changes in the solubility of the DSP and the precipitation of scale.
- Some previous attempts at reducing DSP scale in the Bayer process include adding polymer materials comprising three alkyloxy groups bonded to one silicon atom as described in U.S. Pat. No. 6,814,873 B2; U.S. Patent Application Publication Nos. 2004/0162406 A1, 2004/0011744 A1, and 2005/0010008 A2; International Published Application WO 2008/045677 A1; and published article Max HTTM Sodalite Scale Inhibitor: Plant Experience and Impact on the Process, by Donald Spitzer et. al., Pages 57-62, Light Metals 2008 (2008), all of which contents are incorporated by reference in their entirety.
- At least one embodiment of the invention is directed towards a method for reducing scale in a Bayer process comprising the step of: adding to a Bayer liquor a scale inhibiting amount of polymer having pendant thereto a group or end group containing Formula I:
- n is an integer with a value of either 1 or 2;
- R 1 is one item selected from the list consisting of: H, C 1 -C 12 Alkyl, Aryl, Na, K, Li, and NH 4 ;
- J is selected from the group consisting of H and a hydrocarbon group having a number of carbons within the range of 1 to 20 carbons.
- a 1 and A 2 are each an independent hydrocarbon group having a number of carbons within the range of 1 to 20 carbons or A 1 and A 2 are each independently a direct bond between the nitrogen atom and the adjoining group;
- T and E are each an independent hydrocarbon group having a number of carbons within the range of 2 to 40 carbons;
- Q is selected from the group consisting of H and a hydrocarbon group having a number of carbons within the range of 1 to 20 carbons where:
- R 1 is Na, K, H or C1-C12 alkyl.
- R 1 is Na, K, H or C1-C12 alkyl.
- M is selected from the list consisting of Na, K, Li, and NH 4 .
- X is NH, NR′, or O
- R′ C 1 -C 12 alkyl, or aryl
- FIG. 1 is a flowchart of at least a portion of at least one (simplified) Bayer type process.
- FIG. 2 is an image of a sandy crystalline solid representative of aluminosilicate scale.
- FIG. 3 is an image of a flaky solid representative of scale inhibitor modified aluminosilicate.
- FIG. 4 is an electron microscope image of untreated DSP.
- FIG. 5 is an electron microscope image of DSP treated with a trialkyloxy silane functionalized polymer.
- FIG. 6 is an electron microscope image of DSP treated with a dialkyloxy silane functionalized polymer.
- Polymer means a chemical compound comprising essentially repeating structural units. While many polymers have large molecular weights of greater than 500, some polymers such as polyethylene can have molecular weights of less than 500. Polymer includes copolymers and homopolymers.
- foulant means a material deposit that accumulates on equipment during the operation of a manufacturing and/or chemical process which may be unwanted and which may impair the cost and/or efficiency of the process. DSP is a type of foulant.
- Multiamine means an amine molecule with more than one nitrogen atom.
- polymers such as polyethyleneimine of all molecular weight ranges and small molecules such as diamines, triamines are multiamines.
- Alkyloxy means having the structure of OX where X is a hydrocarbon and O is oxygen. It can also be used interchangeably with the term “alkoxy”. Typically the oxygen is bonded both to the X group as well as to a silicon atom of the polymer.
- X is C 1
- the alkyloxy group consists of a methyl group bonded to the oxygen atom.
- the alkyloxy group consists of an ethyl group bonded to the oxygen atom.
- X is C 3
- the alkyloxy group consists of a propyl group bonded to the oxygen atom.
- X is C 4 the alkyloxy group consists of a butyl group bonded to the oxygen atom.
- X is C 5
- the alkyloxy group consists of a pentyl group bonded to the oxygen atom.
- X is C 6
- the alkyloxy group consists of a hexyl group bonded to the oxygen atom.
- “Monoalkyloxy” means that attached to a silicon atom is one alkyloxy group.
- Dialkyloxy means that attached to a silicon atom are two alkyloxy groups.
- Trialkyloxy means that attached to a silicon atom are three alkyloxy groups.
- Synthetic Liquor or “Synthetic Spent Liquor” is a laboratory created liquid used for experimentation whose composition in respect to alumina, soda, and caustic corresponds with the liquor produced through the Bayer process.
- True Liquor or “True Bayer Liquor” is actual liquor that has run through a Bayer process in an industrial facility.
- FIG. 1 there is shown a flowchart illustrating at least a portion of a Bayer process for manufacturing alumina from raw bauxite ore.
- raw bauxite ore containing silica passes through a grinding stage and alumina together with some impurities including silica are dissolved in added liquor.
- the mixture then passes through a desilication stage where more silica is precipitated as DSP to reduce the amount of Si in solution.
- the slurry is passed on to a digestion stage where more silica dissolves, thus more DSP is formed as the process temperature increases.
- the liquor is later separated from undissolved solids and alumina is recovered by precipitation as gibbsite.
- the spent liquor completes its circuit as it passes through a heat exchanger and back into the grinding stage.
- DSP scale accumulates throughout the Bayer process but particularly at the digestion stage and most particularly at or near the heat exchanger that the recycled liquor passes through.
- a polymer is added to some point or stage in the liquor circuit in the Bayer process, which minimizes or prevents the accumulation of DSP on vessels or equipment along the liquor circuit.
- the polymers resemble those disclosed in WO 2008/045677 except instead of the silane group having a trialkyloxy configuration it instead has a dialkyloxy or a monoalkyloxy configuration.
- Contemplated embodiments include these dialkyloxy or a monoalkyloxy silane group bearing polymers used according to the methods described in WO 2008/045677.
- polymers having silane groups with a dialkyloxy and monoalkyloxy configuration may have a more modulated polarity and reactivity and are better for selectively targeting DSP and not interacting with other Bayer process chemicals and/or reagents.
- the polymer comprises a recurring unit of the Formula (I) and optionally a recurring unit of the Formula (II):
- T and E are each independently a first optionally substituted hydrocarbyl radical comprising from about 2 to about 40 carbons;
- Q is H or a second optionally substituted hydrocarbyl radical comprising from about 1 to about 20 carbons;
- a 1 and A 2 are each independently a direct bond or an organic connecting group comprising from about 1 to about 20 carbons;
- R 1 is an optionally substituted C 1 -C 20 alkyl, optionally substituted C 6 -C 12 aryl, optionally substituted C 7 -C 20 aralkyl, optionally substituted C 2 -C 20 alkenyl, Group I metal ion, Group II metal ion, or NH 4 , where each R 1 is independently selected from H, optionally substituted C 1 -C 20 alkyl, optionally substituted C 6 -C 12 aryl, optionally substituted C 7 -C 20 aralkyl, and optionally substituted C 2 -C 20 alkenyl, Group I metal ion, Group II metal ion, or NH 4 ;
- J is an optionally substituted C 1 -C 20 alkyl, optionally substituted C 6 -C 12 aryl, optionally substituted C 7 -C 20 aralkyl, optionally substituted C 2 -C 20 alkenyl, or H.
- the polymer has a weight average molecular weight of at least about 500; and Q does not contain a silane group.
- the polymer is monoalkyloxy so it has 2 J groups and one OR 1 group bonded to the Si.
- composition comprising a polymeric reaction product of at least a multiamine, a first nitrogen-reactive compound, and a second nitrogen-reactive compound, the polymeric reaction product having a weight average molecular weight of at least about 500, wherein:
- the first nitrogen-reactive compound comprises a J-Si(OR) 2 group and a nitrogen-reactive group, where R and J are each one optionally selected from H, optionally substituted C 1 -C 20 alkyl, optionally substituted C 6 -C 12 aryl, optionally substituted C 7 -C 20 aralkyl, optionally substituted C 2 -C 20 alkenyl, Group I metal ion, Group II metal ion, or NH 4 , each J and R being independently selected from H, optionally substituted C 1 -C 20 alkyl, optionally substituted C 6 -C 12 aryl, optionally substituted C 7 -C 20 aralkyl, and optionally substituted C 2 -C 20 alkenyl, Group I metal ion, Group II metal ion, or NH 4 ;
- the second nitrogen-reactive compound comprises a nitrogen-reactive group and does not contain a silane group, including dialkoxysilane, trialkoxysilane and monoalkoxysilane;
- At least one of the multiamine and the second nitrogen-reactive compound comprises an optionally substituted hydrocarbyl radical comprising from about 2 to about 40 carbons.
- T and E are each independently a first optionally substituted hydrocarbyl radical comprising from about 2 to about 40 carbons;
- Q is H or a second optionally substituted hydrocarbyl radical comprising from about 1 to about 20 carbons;
- a 1 and A 2 are each independently a direct bond or an organic connecting group comprising from about 1 to about 20 carbons;
- R 1 is optionally substituted C 1 -C 20 alkyl, optionally substituted C 6 -C 12 aryl, optionally substituted C 7 -C 20 aralkyl, optionally substituted C 2 -C 20 alkenyl, Group I metal ion, Group II metal ion, or NR 1 4 , where each R 1 is independently selected from H, optionally substituted C 1 -C 20 alkyl, optionally substituted C 6 -C 12 aryl, optionally substituted C 7 -C 20 aralkyl, and optionally substituted C 2 -C 20 alkenyl.
- This can also be in the form of a monoalkyloxy having two J groups and one OR 1 group bonded to the Si.
- monoalkyloxy and dialkyloxy polymers of the trialkyloxy polymers described in U.S. Patent Application Publication Nos. 2004/0162406, 2004/0011744, 2005/0010008, and U.S. Pat. No. 6,814,873 are used to inhibit the growth of DSP scale.
- the polymer added is commercially available (from the Gelest Company of Morrisville, Pa.) dimethoxysilyl-polypropylene oxide, or bis [(3-methyl-dimethoxysilylpropyl)]polypropyleneoxide (CAS number 75009-80-0).
- the composition of matter added to the Bayer process is a “tuned” mixture of different inhibitors targeted towards the specific environment of a specific Bayer process.
- the tuning involves increasing the proportion of more polar alkyloxy molecules in relation to higher concentrations of DSP.
- the tuning involves increasing the proportion of less polar alkyloxy molecules in relation to a higher concentration of other mineral particles such as red mud and Al(OH) 3 .
- trialkyloxy inhibitors are more polar than dialkyloxy polymers, which are themselves more polar than monoalkyloxy polymers.
- Morphology was assessed by visual inspection of the crystalline material resulting from each test.
- One of the polymer inhibitors tested was a commercially available dimethoxysilyl-polypropylene oxide. It appeared to significantly alter the morphology of the resulting crystalline product from sandy to flaky crystals.
- dialkoxysilane modified polymer was synthesized by a method similar to the method disclosed in Example 2 of Published International Patent Application No. WO2008/045677.
- Ten grams of polyethyleneimine (Lupasol WF, BASF) is first diluted in 10.0 g of ethyl alcohol to reduce the viscosity, and then mixed with 2.19 g of glycidoxypropylmethyldimethoxysilane (instead of the trialkyloxy polymer used in WO2008/045677), and 0.64 g glycidyl 4-nonylphenylether. The mixture was maintained at 60° C. for 1 hour and then dissolved in 2% NaOH to make a 10% dialkyloxysilane modified polyethyleneimine.
- reaction mixture gelled in 45 minutes if glycidoxypropyltrimethoxysilane is used.
- the gelled product is very difficult to dissolve in NaOH and therefore very difficult to transfer out of reactors.
- the dialkyloxysilane modified polyethyleneimine was tested in true Bayer process spent liquor.
- the true Bayer liquor had a caustic concentration of 249.84 g/L, and C/S (Caustic/Soda) ratio of 0.82 and A/C ratio of 0.192.
- Sodium silicate solution (40% by weight) was added to the real Bayer liquor at 1.0%, to raise the silica level.
- Dialkyloxysilane modified polyethyleneimine was then added at 50 ppm (active polymer) into the silica-spiked spent liquor and the mixture was poured into a stainless steel cup. The cup was sealed with polymer-coated Al foil and immersed in a heated silicone oil bath at 110° C. for 2 hours without stirring.
- the dialkyloxy silane modified PEI gave 35% less scale.
- the inventive inhibitor is demonstrably effective in inhibiting scale in these conditions.
- FIGS. 4 , 5 and 6 there are shown SEM (Scanning Electron Microscope) images of DSP from true Bayer process liquor.
- FIG. 4 shows DSP from a control sample with no scale inhibitor. The untreated DSP in the control is small fine particles which easily accumulate on process equipment.
- FIG. 6 shows DSP treated by the prior art inhibitor disclosed in WO2008/045677 and
- FIG. 7 shows DSP treated by the inventive dialkyloxy silane polymer.
- the inhibitors reduce the fouling effects of DSP by altering its morphology and size.
- the inhibited DSP particles are much larger spheres which aggregate into flakes that do not accumulate as readily on Bayer process equipment.
- a side effect of the treatment of Bayer liquor with these inhibitors is the production of cubes of sodium aluminum silicate crystals.
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Abstract
Description
-
- the molecular weight of the polymer is at least 500;
- Q does not contain a silane group;
-
- Alumina (A): 84.62 g/L as Al2O3;
- Caustic (C): 238.42 g/L as Na2CO3;
- Ratio of A to C: 0.355.
Claims (18)
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US12/567,196 US8282834B2 (en) | 2009-09-25 | 2009-09-25 | Di- and mono-alkoxysilane functionalized polymers and their application in the Bayer process |
US13/645,613 US8501010B2 (en) | 2009-09-25 | 2012-10-05 | Di- and mono-alkoxysilane functionalized polymers and their application in the Bayer process |
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WO2014137528A1 (en) * | 2013-03-08 | 2014-09-12 | Nalco Company | Reducing aluminosilicate scale in the bayer process feed strategy for dsp inhibitor |
WO2015100196A1 (en) | 2013-12-24 | 2015-07-02 | Cytec Industries Inc. | Method of reducing scale in the bayer process |
TWI651434B (en) * | 2014-10-21 | 2019-02-21 | 美商塞特工業公司 | Degradation-resistant scale inhibitors |
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US20040011744A1 (en) * | 2002-07-22 | 2004-01-22 | Spitzer Donald P. | Method of preventing or reducing aluminosilicate scale in a bayer process |
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US5118484A (en) | 1990-08-17 | 1992-06-02 | Alcan International Limited | Desilication of bayer process solutions |
US5314626A (en) | 1991-12-23 | 1994-05-24 | Nalco Chemical Company | Method for the alteration of siliceous materials from Bayer process liquids |
US5415782A (en) | 1993-11-22 | 1995-05-16 | Nalco Chemical Company | Method for the alteration of siliceous materials from bayer process liquors |
US5650072A (en) | 1994-04-22 | 1997-07-22 | Nalco/Exxon Energy Chemicals L.P. | Sulfonate and sulfate dispersants for the chemical processing industry |
EP0767727B1 (en) | 1994-06-28 | 1998-09-09 | Anglian Windows Limited | Formed foamed plastics material |
US5733459A (en) | 1996-04-29 | 1998-03-31 | Cytec Technology Corp. | Use of hydroxamated polymers to alter bayer process scale |
US5733460A (en) | 1996-04-29 | 1998-03-31 | Cytec Technology Corp. | Use of hydroxamated polymers to alter Bayer Process scale |
US6569908B2 (en) | 2000-01-19 | 2003-05-27 | Oji Paper Co., Ltd. | Dispersion of silica particle agglomerates and process for producing the same |
GB2382813B (en) | 2000-06-26 | 2004-07-14 | Asahi Chemical Ind | Porous inorganic fine particles |
DE102004017034A1 (en) | 2004-04-02 | 2005-10-20 | Stockhausen Chem Fab Gmbh | Use of copolymers to reduce precipitates and deposits by inorganic and organic impurities in the Bayer process for the production of aluminum hydroxide |
US7161550B2 (en) | 2004-04-20 | 2007-01-09 | Tdk Corporation | Dual- and quad-ridged horn antenna with improved antenna pattern characteristics |
FR2870535B1 (en) | 2004-05-18 | 2007-02-16 | Aluminium Pechiney Soc Par Act | IMPROVEMENT TO THE BAYER PROCESS FOR THE PRODUCTION OF ALUMINA TRIHYDRATE BY ALKALINE CONTAMINATION OF BAUXITE, THIS METHOD COMPRISING A PRE-ASSESSMENT STEP |
GB0415227D0 (en) | 2004-07-07 | 2004-08-11 | Accentus Plc | Precipitation of silica in a Bayer process |
US10227238B2 (en) | 2006-04-04 | 2019-03-12 | Ecolab Usa Inc. | Production and use of polysilicate particulate materials |
JP5543208B2 (en) | 2006-10-13 | 2014-07-09 | サイテク・テクノロジー・コーポレーシヨン | Hydrophobic modified polyamine scale inhibitor |
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US20040011744A1 (en) * | 2002-07-22 | 2004-01-22 | Spitzer Donald P. | Method of preventing or reducing aluminosilicate scale in a bayer process |
US20040162406A1 (en) * | 2002-07-22 | 2004-08-19 | Spitzer Donald P. | Method of preventing or reducing aluminosilicate scale in a bayer process |
US20050010008A2 (en) * | 2002-07-22 | 2005-01-13 | Cytec Industries, Inc. | Method of preventing or reducing aluminosilicate scale in a bayer process |
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